Beruflich Dokumente
Kultur Dokumente
60
ekrPro Com
with analog sensors
Warning signs
Symbols are used in this operating manual in order to clearly
indicate particularly important places.
Attention!
Beware!
You must obey by this type of warning without fail, in
order to protect yourself, as the operator, from life
threatening injuries caused by electrical voltages.
Note
This symbol is used to point out additional useful tips,
which will help you to make optimum use of all of the
functions.
Press key.
LED off
LED flashing
Table of contents
Section B Commissioning
Section C Operation
Section D Appendix
Section A
General information
A1 Description
A2 Specifications
A3 Transport / Storage
A4 Decommissioning
Section A
General information
Symbols used in this manual
Table of contents
A1 Description A1-1
A 1.1 General information A1-1
A 1.2 Utilisation A1-1
A 1.3 Housing versions A1-1
A 1.4 General definitions A1-2
A 1.4.1 Assignment of sensors to the guiding mode A1-2
selection keys
A 1.4.2 Inverting of the sensor signal A1-3
A 1.4.2 Size of oscillation amplitude related to sensor
scanning area A1-3
A 1.4.2 Oscillation types and curves A1-4
A 1.4.2 Allocation of FVGs for a FVGPro 2MK A1-4
A 1.5 Connectable components A1-4
A 1.6 Safety information A1-5
A 1.7 Emissions A1-5
A2 Specifications A2-1
A 2.1 ekrPro Com60 controller (version XT) A2-1
A 2.2 Optical edge sensor IR2001, IR2005 A2-3
A 2.3 Optical edge sensor IR2002 A2-3
A 2.4 IRS-U-2 A opto-electronic analog sensor A2-3
A 2.5 Ultrasonic edge sensor US2003, US2007, US2008 A2-4
A 2.6 Reflecting sensor TW 54 C 5 A2-4
A 2.7 Line sensor T 62 D 1 A2-5
A 2.8 Reflected light measuring light barrier R 42 D ... A2-5
A 2.9 Photoelectric fork sensor G 53 C2/5 A2-6
A 2.10 Switched power pack A2-7
A4 Decommissioning A4-1
A 1 Description
The aim of the operating manual is to enable you to use the
guiding system rapidly by explaining the basic settings for initial
start-up (start-up menu) and the conventional functions for
operation. In addition, the complex functions will be described
using selected examples for setting certain parameters.
A 1.1 General information
This family of control systems includes:
• ekrPro Com60: Controller with keyboard
• ekrPro Key60: External control keyboard.
Devices in the controller family can be interconnected at different
levels into a system network via a CAN-Bus.
A 1.2 Utilisation
The ekrPro Com60 is a microprocessor controlled web guiding
controller. Together with other BST components it may be used for:
There are also standard PLC compatible inputs and outputs as well
as an OK-reporting system present.
A 1.4 General
Settings
Sensor right
Sensor left (Sensor 2)
(Sensor 1)
Sensor right
(Sensor 2)
Sensor left
Not permitted:
► Sensor:
Invert!
FVG 1
>>> <<<
Web travel direction <<< >>>
FVG 2
internal
limit switch
external
limit switch
A 1.5 Connectable
components
The general plan (annex C2) shows the components that can be
connected to the ekrPro Com60 controller.
A 2 Specifications
Controller output stage 1x DC motor 24V DC, max. 3 A, short circuit protected.
Select voltage, current or tachometer control (in preparation)
PWM 20 kHz
FVG output stage 1 x stepping motor, max. 1.5A; not short circuit protected
160
140
240 70
105
max. 10
115 15
205
1. Central supply
If supply takes place centrally from the machine the following
parameters are to be fulfilled:
• Output voltage: 24 V DC ± 5%
• Output current: 4.2 A DC
• Output power: 100 W
The power pack must be able to quickly charge (~ 5 sec) the input
capacitance (approx. 950µF) of the control amplifier after switching
on without recognizing this as a short circuit and so switching off
again.
The output should be permanently resistant to short-circuiting,
overloading and idle running.
A 3 Transport
A 4 Decommissioning
Section B
Commissioning
B1 Installation
B2 Controls
B3 Commissioning
B4 Terminal assignments and service displays
Section B
Commissioning
Symbols used in this manual
Table of contents
B1 Installation B1-1
B 1.1 Installation site requirements B1-1
B 1.2 Installation ekrPro Com60 (Mounting unit) B1-1
B 1.2.1 Securing hole diagram B1-1
B 1.2.2 Installation B1-1
B 1.3 Installation ekrPro Com60 Desk (Built-in unit) B1-2
B 1.3.1 Installation dimensions B1-2
B 1.3.2 Cabling B1-2
B 1.3.3 Installation B1-3
B 1.4 Installation instructions for EMC-wiring B1-4
B 1.5 Installation contrast/line sensor B1-5
B 1.5.1 Sensor arrangement B1-5
B 1.5.2 Installation line sensor T 62 D 1 B1-6
B 1.5.3 Installation reflection sensor TW 54 C 5 B1-7
B3 Commissioning B3-1
B 3.1 General information B3-1
B 3.2 Electrical connections B3-2
B 3.3 Commissioning with a CAN bus B3-3
B 3.3.1 Check unit address or set up if necessary B3-3
B 3.3.2 Terminator activation B3-5
B 3.4 Adjust password B3-7
B 3.5 Commissioning standard system B3-9
B 3.5.1 Select standard system B3-9
B 3.5.2 Carry out master setup B3-10
B 3.5.3 Setting the actuator guiding direction B3-11
B 3.5.4 Setting the actuator path limits B3-11
B 3.5.5 Servo centre position and amplification for the B3-12
“SC” operating mode
B 3.5.6 Carry out material setup B3-13
B 3.5.6.1 Automatic material set-up B3-14
B 3.5.6.2 Manual material set-up B3-14
B 3.5.7 FVG - Sensor positioning device B3-15
B 3.5.8 Additional Functions B3-19
B 3.5.8.1 Tear Off Detection B3-19
B 3.5.8.1 Oscillation B3-23
B 3.6 Save settings B3-25
B 1 Installation
Ø6
125
B 1.2.2 Installation
B 1.3 Installation
ekrPro Com60 Desk
(built-in unit)
Section
B 1.3.2 Cabling
Attention!
A space of at least 140 mm must be guaranteed for the
cabling in order to ensure that the cables are laid
correctly (see illustration).
min. 140
B 1.3.3 Installation
max. 10
Attention!
A free area of at least 300 mm in front of the
housing must be guaranteed so that it can be
opened.
housing wall
Union nut
Intermediate supports
B 1.5 Installation
contrast / line sensor
Connection
cable
TW 54 C 5
T 62 D 1
Material web
→ Contrast transition
BRIGHT/DARK
→ Contrast transition
DARK/BRIGHT
B 1.5.2 Installation
line sensor T 62 D 1
T 62 D 1
17
ø8
Deflection roller
Scanning arrangement T 62 D 1
B 1.5.3 Installation
reflection sensor TW 54 C 5 5°…15° 5°…15°
TW 54 C 5
6…12
Only one contrast transition may be located within the light spot.
Keypad
The controller can be configured for operation using this keypad.
Key Function
Automatic guiding
Manual positioning
Key Function
Menu selection
Shortcut functions
1 Current position
in device menu
Assignment of allocated
function keys
51
12 3 45 6 789 0
The required dialog will be displayed and you can now use the
arrow keys to select the parameter that has to be modified.
The parameter values are entered directly in the editing box. This
can also be realised using the F-keys.
1. Open the required sub-menu and then press the ENTER key
to activate the editing box.
Editing box
The arrow keys can also be used to enter a value in the editing box
in addition to using the F-keys.
Now use the vertical arrow keys so that the minus sign
is entered or removed.
Control elements
Use the arrow keys to mark the required control if there are several
control elements displayed in the same dialog window.
For example:
sens.mode W XP
0 5.00
0 5.00
0 5.00
0 5.00
Option lists
An entry from a default list can be selected from an option list. This
is realised by pressing the ENTER button to open the selected
option list.
Example:
EMS 17 EMS 10
EMS 16
EMS 17
The “▼“ or “▲“ symbols displayed on the right of the option list
indicate that there are more entries in list than are displayed on the
screen.
Checkbox
Example:
X = Option active
active X
= Option inactive
Read-only Checkbox
Example:
= activated
= not activated
B 2.2.3 Buttons
Button control elements are present in certain dialog windows
B 3 Commissioning
B 3.1 General information
The controller ekrPro Com60 is matched to the actual configuration of
the control system (connected sensors, actuator, sensor adjustment
unit, ...) using the system parameters in the individual setup menus.
The required parameters have already been entered if the control
system is an integral part of a projected BST system. You do not
have to reset anything with regard to this.
A new system configuration is required if components or the
controller have been exchanged on-site.
The range of the settings and therefore the set-up menus that have
to be taken into consideration depend on the system being used.
Check that all the cables are fitted tightly after the connections have
been made (in both cases).
B 3.3 Commissioning
with a CAN Bus
B 3.3.1 Checking the unit address
and setting up if necessary
If the ekrPro Com60 controller is operated via a CAN bus, then the
setting of the CAN device address must be checked.
The CAN device address setting up is carried out via the S1 BCD
switch on the processor board:
BCD switch S1
Procedure:
1. Switch-off the power to the controller.
2. Open controller’s front cover.
3. Set S1 BCD switch to the required device address (1 – 8).
4. Close the controller’s front cover.
5. Restore the power.
Procedure:
1. Switch-off the power to the controller.
S1 BCD switch
2. Remove the plug.
3. Check setting of BCD switch S1. If necessary, set
device address to S1 = 1.
4. Refit the plug.
5. Restore the power.
Procedure:
1. Switch off the power to the FVG Pro module.
2. Open housing’s front cover.
3. Check the setting of the BCD switch S1. If
necessary, set device address to S1 = 1.
4. Close the controller’s front cover.
5. Restore the power.
S1 BCD switch
Terminator S3
Procedure:
1. Switch-off the power to the controller.
2. Open controller’s front cover.
3. Activate terminator S3 (switch position ON)
4. Close the controller’s front cover.
5. Restore the power.
Switch S3
In the BST ProLogic activation takes place using the DIP switch
segment 1 (S1 = ON) for the CAN 1.
CAN 2
Switch S3
Procedure:
1. Switch-off the power to the module.
2. Open module’s front cover.
3. Activate terminator S3 (switch position ON)
4. Close the module’s front cover.
5. Restore the power.
An automatic logout time can be set for all user levels (timeout time).
If no key is pressed for the set time, the user is automatically logged
out and the controller changes to the user level Operator.
Enter user level & password Press the ENTER button and the user level option list will then
User level
Password
Operator
Mainten. be opened.
Current Admin. Select the desired user level with the up and down arrow
user level BST Support
keys.
123 456 789 0 Confirm the selection by pressing ENTER.
5. Use the vertical arrow keys to select the system that matches
the present system.
Confirm the selection with the ENTER key.
The selected system is displayed.
Change User
1. Select Actuator in General Setup, then the sub-directory
Actuator
Material Setup
TypeType
(EMS&Hydr.) SC-Component and finally Pos. Limit.
System & Dir.
Sel.Sensors/EFE
Std. Hydraulics
Control
General SetupLoop
Directions
Add-on
Pos. Limit Confirm the respective selection by pressing ENTER.
FVG SC W & XP
opt. LogicSC-Transducer
From here the centre position and the amplification for operating
mode SC are set.
6. The setpoint value setpoint W and the gain gain XP can also
be entered directly in the relevant window.
<<<
7%
dark bright Material set-up can now be carried out either automatically or
-2048 abs. 1775 2047
auto dark bri.
manually.
The manual procedure should always be used if the contrast that
has to be scanned is critical.
This completes the material set-up for this sensor. Material set-up is
finished when the same procedure has been carried out for any
other sensors connected to the controller.
The sequence is arbitrary, i.e. the dark setting (steps 1 and 2) or the
bright setting (steps 3 and 4) can be made first.
For sensors TW54 and T62, you must use the special
Material-Setup – Sensor 3 (see Point C 2.3.4).
The connection cable from the ekrPro Com60 control unit to the
sensor adjustment unit must not exceed the maximum cable
length of 20 m.
- Offset 2:
• at the first setting after switching on:
Offset = 2000
Inverted = yes
Slide 1
- Homing Direction – retraction direction and limit switch
assignment
• at the first setting after switching on: not
reversed
Slide 2
- Homing Direction – retraction direction and end switch
assignment
• at the first setting after switching on: not
reversed
Interrupted printed
or contrast edge
Tear-off
inwards
Tear-off
outwards
Light spot
d L
Example calculation:
At a maximum web speed vmax = 300 m/min and a light spot
diameter d = 8 mm the resultant minimum mark length Lmin,
equals:
300 m/min 8 mm
Lmin = ¹ 3 ¹ 0,004 s ¬
60 s/min 1000 mm/m
Lmin = 0,068 m = 68 mm
Operating mode
selection switch
Parameter settings
3. This will open up the inputting window for the selected guiding
mode. The following separate parameters can be set:
Example calculation:
At a minimum web speed vmin = 30 m/min and a light spot diameter
d = 10 mm the resultant maximum rate of change of the sensor
signal equals:
30 m/min
sig. chg. limit [%/4ms] = 2 ¹ ¹ 100
60 s/min * 10 [mm]
B 3.5.8.2 Oscillation
2. The set value for the web width (Nominal Width) is entered in
this window. Activation then takes place in the operating
status display using the F1 key.
The following settings are possible:
► start/stopp at act.pos:
Oscillation Add-on:
When the function is activated, the
oscillation will continue at the position
>> NOT FOR FVG OSC.!<< where it was stopped.
De f. Set.
1. Press the MENU button, select General Set-up from the sub-
menu and then press ENTER.
Material Setup
Actuator
3. The default actuator will be displayed on the screen.
Sel. Std. Type
System
Sensors/EFE
Save/Load
(EMS&Hydr.)
Settings Add-on
Press the ENTER button and the actuator option list will then
Hydraulics
Control
General SetupLoop
Direction be opened.
opt.FVG
LogicSC-Transducer
Now use the vertical arrow keys to select the actual actuator
12 3 45 6 789 0 that is connected to the system.
Select an actuator type Press the ESC button to exit the window.
EMS 10
EMS 16
EMS 17
HR 024 300 mA 1* No
HR 040 300 mA 20 0 No
Oil blocking is only active with a hydraulic actuator and when one of
the following conditions is fulfilled:
• Man output = 0 and position controller deactivated.
• A limit switch position is reached.
• An over-temperature and a short circuit exist.
• Missing enable for the actuator:
(see actuator enable terminal 53)
B 3.7.5.2.4 SC Transducer -
Servo-center component settings
5. Drive the actuator using the F2 key, while monitoring the bar
indicator in the display.
Position feedback via the servo-center component must be
configured so that when the actuator is driven, the black bar
on the left side gets smaller.
If the length of the black bar increases when the F2 key is
pressed, inverting is to be switched on by selecting the check
box Inv..
Pos. Limit –
Setting the actuator path limits (software limit switches)
SC W & XP –
Setting the centre position and the gain for the SC operating mode
5. Press the F4 key if you want to save the actual position as the
set point for the servo-center position.
The setting from mot.pos. will be imported into setpoint W.
6. The setpoint value setpoint W and the gain gain XP can also
be entered directly in the relevant window.
To test the set positioning speed move the actuator using the
F2 and F3 keys.
The types of the sensors that are actually connected can be set up
in the sub-menus Sensor 1, Sensor 2 and Sensor 3.
The parameters for the control circuit are set up in this sub-menu.
2. Mark Gain & Offset in the selection window and then confirm
by pressing ENTER.
3. This will open up a window for the set point value and gain
settings.
The set value (W) for the web position and the gain setting
(XP) can be set up separately here for each of the guiding
modes.
We recommend that you should use the factory default
settings for standard controllers.
active X
B 3.7.5.5 FVG –
Sensor positioning device
The control unit integrated in the controller for running the sensor
positioning device can be parameterised in this sub-menu.
A stepping motor drives the sensor adjustment unit.
The stepping motor output stages are not protected against
short circuits.
You must check, without fail, using a suitable test unit
(ohmmeter) that no short circuits or cross-connections
between the two windings exist before starting the
commissioning.
The connection cable from the ekrPro Com60 control unit to the
sensor adjustment unit must not exceed the maximum cable
length of 20 m.
Power is continuously applied to the stepping motor output
stage, even when stopped. Therefore any work undertaken on
the interconnections must only be carried out with the power
switched off.
The FVG function has been set to not activated in the factory, i.e.
no further settings are required if an FVG is not connected to the
system.
Once the selection has been made, specific settings must be carried
out for the FVG eco, FVG 1MK Op. and FVG 2MK Op. modes.
Homing Direction –
Retraction direction and limit switch assignment
1. Mark Int. FVG in the FVG selection window and then confirm
by pressing ENTER. Select Homing Dir. from the sub-
directory and then press ENTER to open the inputting menu.
Change User
Actuator
Material Setup
Connected
Sel.Sensors/EFE
Std. Homing
Control
System Dir.
Loop
2. Press the F1 key to check the selected retraction direction.
General Setup
FVG
Retract Mode
opt. LogicErr. Behaviour By pressing the F1 key, the FVG slide must move outwards
(into the homing position).
123 456 789 0
After the homing position is reached, the limit switch with the
outer label must be activated ( ).
Exit the window without making any changes if the homing
direction and limit switch assignment are correct.
If the FVG slide moves inwards when the F1 key is pressed,
then the checkbox Homing dir. inv. should be activated.
If the limit switch with label inner is activated in the homing
position, then the checkbox Ref. switch inv. should be
activated.
3. Press the ESC button to exit the inputting menu after you
have entered the setting.
The outside FVG1 limit switch has been determined as the reference
point for the FVG slide (offset = 0.0 mm)
Offset
Offset 2 (FVG)
FVG 1
FVG 2
Web running
direction
absolute position
Fixed point in the machine
(e.g. machine wall
Home position
[Dist. from home = 0.0 mm]
4. Press key F1 to run the sensor to the park position so that you
can draw in the web at a later point.
5. Press the ESC button to exit the inputting menu after you
have entered the settings.
If you are now working with a position offset, this does not need to
be referred to in this dialog window.
This setting is treated as the feed per motor revolution for the
stepping motor / gearing combination.
The manufacturer has entered this default setting and you are only
permitted to modify it (if necessary) after having obtained the
manufacturer’s agreement.
The relevant procedure then has to be agreed.
All warranty claims will be invalidated in any other case.
The safety features are identical for both FVGs. The procedure for
FVG 1 (Slide 1) is used as the example here:
Homing Direction –
Retraction direction and limit switch assignment
4. Press the ESC button to exit the inputting menu after you
have entered the setting.
Offset –
positional offset to position of first FVG slide
You can create a reference system with an absolute reference point
using the positional offset. This reference point can, for example, be
the machine wall or another obvious point on the machine. It is also
possible to use an outer position or the centre of the FVG. If the
centre of the FVG is used, one of the FVG slides will move in a
negative direction.
The offset value is added to the current FVG position and results in
the absolute distance to this reference point (Abs. slide pos.).
Example:
FVG 1
Offset FVG 1
FVG 2
Reference point
(zero position) Offset FVG 2
Tape measure
FVG 1
4. Now compare the value shown under Abs. slide pos. with
the measured value.
If the measured value is larger and the displayed value
smaller, then you must activate the inverted checkbox.
5. Carry out settings for the second FVG slide (Slide 2) in the
same manner.
The standard operating display now shows the position of the centre
of the measurement window belonging to the appropriate sensor
based on the reference point.
Range –
Traversing range limits for first FVG slide
5. Press the ESC button to exit the inputting menu after you
have entered the settings.
Feed –
Feed for stepping motor/gearing combination
This setting is treated as the feed per motor revolution for the
stepping motor / gearing combination.
The manufacturer has entered this default setting and you are only
permitted to modify it (if necessary) after having obtained the
manufacturer’s agreement.
The relevant procedure then has to be agreed.
All warranty claims will be invalidated in any other case.
The retract mode determines when the FVG will traverse into the
park position (home position) after a specific operating mode
change.
Change User
Actuator
1. Select Retract Mode from the sub-directory and then press
Material Setup
Connected
Sel.Sensors/EFE
Std. Homing
System Dir. ENTER to open the selection menu.
Control
General SetupLoop
Retract Mode
FVG
opt. LogicErr. Behaviour
2. The following retract modes are available in the selection
123 456 789 0 menu:
3. Press the ESC button to exit the inputting menu after you
have made the selection.
123 456 789 0 • Bright/Dark: Both bright and dark setting standardisations
will be carried out.
This standardisation mode is normally used
for infrared sensors with film material.
3. Press the ESC button to exit the inputting menu after you
have made the selection.
B 3.7.5.5.7 - Width Adjust – FVG operating mode for center line guiding
Use Width Adjust to select FVG operating mode for center line
guiding.
25% covering
Start of sensor tracking
50% covering
End position
75% covering
Start of sensor tracking
3. Press the ESC button to exit the inputting menu after you
have made the selection.
Sensor-cover-guarding:
This monitoring function prevents destruction of the material
web due to unwanted contact with the sensors.
If the coverage of the sensor scanning area, with the
checkbox activated, exceeds 90 % of full coverage, then the
FVG slides are automatically stopped.
The reference width value last entered remains saved when the
device is switched off.
Important:
The calibration sheet reference dimension can change marginally
due to the effects of heat. Information relating to various
temperatures is given on the calibration sheet.
To obtain the best results, use the reference dimension for the
temperature which is nearest to the actual temperature, or
interpolate the dimension between these two temperatures.
The set value for the web width (Nominal Width) is entered in this
window. The lower and upper error limits (E+, E-) and the lower and
upper warning limits (W+, W-) are also set up here. The measuring
unit is mm.
These are the entries which form the basis for the operating display
when the web width measurement is active.
Five conditions are indicated.
W+
c) Material width is too small when related to the lower warning
limit;
it lies in the W- area (24V DC at output 65).
Material width
W-
d) The material width lies outside the absolute tolerance.
It lies in the error limit areas E+ (24 VDC at output 66)
Material width
E+
e) The material width lies outside the absolute tolerance.
It lies in the error limit areas E- (24 VDC at output 65)
Material width
E-
Digital message outputs are available for the limits.
The meaning and allocation of messages relating to digital
outputs are described under Point B 3.7.5.9.2.
2. Enter the nominal value for the material width in the edit field
Nominal Width.
3. Enter selected values for the error and warning limits in the
corresponding edit fields.
80.0
-5.0
5.0
-2.0
4. Press the ESC button to exit the window after you have
2.0 entered the settings.
You can use this window to determine in which operating modes the
width measurement is able to be implemented.
This makes it also possible to carry out a web width measurement
without an FVG if the checkbox has been activated for the
corresponding operating mode.
3. Press the ESC button to exit the window after you have
entered the settings.
Edge 1 Edge 1
Edge 2 Edge 2
3. Select sample mode using the vertical arrow keys and press
ENTER.
7. Select the option list edge using the horizontal arrow keys and
press ENTER.
8. Select the sensor from the option list to whose input signal the
selected sample mode is to be assigned and press ENTER.
3. This will open up the inputting window for the selected guiding
mode. The following separate parameters can be set:
B 3.7.5.8.2 Oscillation
This special function enables the position of the web of material to
be displaced within the sensor´s visual range using adjustable
amplitude (size of the lateral displacement) and frequencies
(displacement speed).
The format of the web displacement when the controller is operated
without a sensor positioning device follows a delta curve ( ).
When operated with a sensor positioning device, a sine-wave ( )
web displacement takes place. See also chapter A1, Point A 1.4.4‚
Oscillation types and curves’.
2. The set value for the web width (Nominal Width) is entered in
this window. Activation then takes place in the operating
status display using the F1 key.
The following settings are possible:
B 3.7.5.9.1 Configure –
selection of digital input table and activation of inputs/outputs
You can select from two tables in this dialog window. Both
contain various assignments for the digital inputs (see Point
B 3.7.5.9.3).
The tables are created so that they cover most of the
applications controllable using digital inputs, which helps
avoid time-consuming configurations.
Specific adjustments can, however, still be carried out if
required.
The procedure is described under Point B 3.7.5.9.2.
Both digital inputs and outputs can be switched off for initial
startup. Please deactivate the appropriate checkboxes to do
this.
B 3.7.5.9.2 Inputs –
Digital inputs
7. Select the option list using the horizontal arrow keys and open
Truth Table Pattern by pressing ENTER.
no. assigned function
30 Tear Out OFF
Bitmask
85 0 74
8. Select the function Tear Out OFF (tear-off detection OFF)
using the vertical arrow keys and press ENTER.
Ln Ln deac t.
Assignment of the function Tear-off detection to the digital
inputs is now completed.
The following section of the truth table shows that lines 21 and 22
belong to a bit-block with a total of 8 lines (lines 21 to 28).
The procedure for changing the allocations can be divided into three
steps, which are described on the following page.
Procedure:
The value for all the non-relevant bits (terminal 83) of the
two lines 21 and 22 must be set to the value "X"
(not relevant).
Terminal
Line Significance 85 84 83 82 81 80 79 78 77 76 75 74
1 set Auto X X X X X X X X X 1 0 0
(automatic mode)
2 set MAN X X X X X X X X X 0 0 1
(manual mode)
3 set SC X X X X X X X X X 0 1 0
(servo center position)
4 opmode clear X X X X X X X X X 0 0 0
(defined zero state operating mode)
5 set Edge1 X X X X X X 0 0 1 X X X
(edge 1)
6 set Edge2 X X X X X X 0 1 0 X X X
(edge 2)
7 set Center1&2 X X X X X X 0 1 1 X X X
(center 1/2)
8 set Edge3 X X X X X X 1 0 0 X X X
(edge 3)
9 set Edge3 Inv. (inverse edge 3) X X X X X X 1 0 1 X X X
10 guid.mode clear X X X X X X 0 0 0 X X X
(defined zero state guiding mode)
11 Motor stop X X X 0 0 0 X X X X X X
12 Motor stop X X X 0 0 1 X X X X X X
13 FVG stop X X X 0 0 0 X X X X X X
14 FVG stop X X X 0 0 1 X X X X X X
15 Motor left X X X 0 1 0 X X X X X X
16 FVG left X X X 0 1 1 X X X X X X
17 Motor right X X X 1 0 0 X X X X X X
18 FVG right X X X 1 0 1 X X X X X X
19 Motor stop X X X 1 1 0 X X X X X X
20 FVG stop X X X 1 1 1 X X X X X X
21 Set Lim.Sw. 1 X 1 0 X X X X X X X X X
(stop switch 1)
22 Reset Lim.Sw. 1 X 0 0 X X X X X X X X X
(reset stop switch 1)
23 Reset Lim.Sw. 1 X 1 1 X X X X X X X X X
(reset stop switch 1)
24 Set Lim.Sw. 2 X 0 1 X X X X X X X X X
(stop switch 2)
Terminal
Line Significance 85 84 83 82 81 80 79 78 77 76 75 74
25 Reset Lim.Sw. 2 X 0 0 X X X X X X X X X
(reset stop switch 2)
26 Reset Lim.Sw. 2 X 1 1 X X X X X X X X X
(reset stop switch 2)
27 Set Overtemp. X 1 1 X X X X X X X X X
(over-temperature)
28 Reset Overtemp. X 0 0 X X X X X X X X X
(reset over-temperature)
29 Keyb.Lock ON 1 X X X X X X X X X X X
(keyboard interlock on)
30 Keyb.Lock OFF 0 X X X X X X X X X X X
(keyboard interlock off)
31 - Do Nothing 1 1 1 1 1 1 1 1 1 1 1 1
60 (reserved)
Terminal
Line Significance 85 84 83 82 81 80 79 78 77 76 75 74
1 set Auto X X X X X X X X X 1 0 0
(automatic mode)
2 set MAN X X X X X X X X X 0 0 1
(manual mode)
3 set SC X X X X X X X X X 0 1 0
(servo center position)
4 opmode clear X X X X X X X X X 0 0 0
(defined zero state operating mode)
5 set Edge1 X X X X X 0 0 0 1 X X X
(edge 1)
6 set Edge2 X X X X X 0 0 1 0 X X X
(edge 2)
7 set Center1&2 X X X X X X 0 1 1 X X X
(center 1/2)
8 set Edge3 X X X X X X 1 0 0 X X X
(edge 3)
9 set Edge3 Inv. (inverse edge 3) X X X X X X 1 0 1 X X X
10 guid.mode clear X X X X X X 0 0 0 X X X
(defined zero state guiding mode)
11 Shifted Center OFF X X X X X 0 X X X X X X
12 Reset Prepos. Center X X X X X 1 X X X X X X
(reset pre-positioning to centre)
13 Shifted Center ON X X X X X 1 X X X X X X
14 Set Prepos. Center X X X X X 0 X X X X X X
(pre-positioning to centre)
15 set Center1&2 X X X X X 1 X X X X X X
(center 1/2)
16 FVG left X X X 0 1 X X X X X X X
17 FVG right X X X 1 0 X X X X X X X
18 FVG stop X X X 1 1 X X X X X X X
19 FVG stop X X X 0 0 X X X X X X X
Terminal
Line Signification 85 84 83 82 81 80 79 78 77 76 75 74
20 Set limit switch 1 X 1 0 X X X X X X X X X
21 Reset Lim.Sw. 1 X 0 0 X X X X X X X X X
22 Reset Lim.Sw. 1 X 1 1 X X X X X X X X X
23 Set Lim.Sw. 2 X 0 1 X X X X X X X X X
24 Reset Lim.Sw. 2 X 0 0 X X X X X X X X X
25 Reset Lim.Sw. 2 X 1 1 X X X X X X X X X
26 Set Overtemp. X 1 1 X X X X X X X X X
27 Reset Overtemp. X 0 0 X X X X X X X X X
28 Ext. Unlock 1 X X X X X X X X X X X
29 Ext. lock 0 X X X X X X X X X X X
30 - Do Nothing 1 1 1 1 1 1 1 1 1 1 1 1
60 (reserved)
Controller interlock
The controller interlock is generally activated. The function can only
be deactivated by application of a "1” signal (24 V=) to terminal 53.
If the controller block is activated, the output of the output stage is
switched off.
The actuator will not carry out any guiding movements.
This is valid for all operating or guiding modes (AUTO, MAN, SC).
Keyboard interlock
All of the controller’s keys are locked by a “1“ (24 VDC) on
terminal 85. The controller can be controlled via the keyboard when
this signal is no longer set.
The individual lines in the truth table can each be allocated the
following meaning:
B 3.7.5.9.4 Outputs –
Digital outputs
3. Select the option list for the desired terminal (64 – 67) using
the horizontal arrow keys and press ENTER.
Dig. Outp. Cond. Low act.
64 no Errors
65 W. warn nor err. min.
66 W. warn nor err. max.
4. In the opened option list mark the message that is to be
67 Hyd. Lock allocated to the selected terminal and press ENTER.
def.
5. Set interface conditions for the signal via the checkbox
Low act..
Signal = high active Î deactivate checkbox
Signal = low-active Î activate checkbox
6. Press the "ESC" button to exit the window after allocating the
messages.
Report Significance
This window is used to set the password for current active user level
and the timeout time for an automatic logout.
The password consists of a maximum of 5 figures (0 ...9).
If no key is pressed for the duration of the set timeout time, the user
is automatically logged out and the user Operator is activated.
4. Use the right and left arrow keys to select the Password
editing box and press ENTER.
Set Password using F2 6. Finally to store the new password, press the F2 key.
Set Timeout using F3
User level: Admin
Password 0 7. Use the right and left arrow keys to select the Timeout [min]
Timeout [min] 0
editing box and press ENTER.
st.pwd set t/o
8. Enter the new timeout value and confirm the entry with
ENTER.
If the timeout time is set to “0”, then no automatic logout
occurs.
Input of a timeout time greater than 0 prevents a user with
extensive user rights from forgetting to log him(her)self out.
3. This will open up the unit settings window for the general
device settings. This contains the following separate
parameters:
B 3.7.7 Fieldbus
It is possible to integrate a relevant field bus module to link into the
customer’s control system / network.
A separate menu branch is also provided for this.
This part of the set-up menu enables the operator to modify or read
out the configuration settings for the field bus version that is being
used.
No settings can be entered unless the field bus connection has been
set up.
In this case the field bus status window only displays the information
unknown (field bus has not been detected).
INDEX
Adjust password .............................................. 7 Material set-up
CAN-Bus Automatic .......................................................... 14
Checking and setting up the unit address .......... 3 Manual .............................................................. 14
ekrPro Com60 ............................................. 3 Sensor compensation ....................................... 26
ekrPro Key60............................................... 4 Save settings ................................................... 25
FVGPro Module........................................... 4 Setup-Menu ..................................................... 26
Commissioning ................................................... 3 Change User - Selection of user level .............. 26
Terminator activation .......................................... 5 Fieldbus............................................................. 71
BST ProLogic .............................................. 6 Optional logic .................................................... 71
ekrPro Com60 ............................................. 5 Remote control via CAN bus ............................ 72
ekrPro Key60............................................... 5 Save/Load Settings........................................... 26
FVGPro Modul............................................. 6 Selection of a standard system......................... 26
Elecrical connections....................................... 2 Sensor compensation ....................................... 26
General information ......................................... 1 System parameters........................................... 27
General Setup Special functions
Actuator settings............................................... 28 Oscillation.......................................................... 23
Assignment of the sensors to the scanning Tear off detection .............................................. 19
modes ........................................................... 54 Standard system
Commissioning sensors and EFE .................... 35 Carry out master setup ..................................... 10
Configuration of the digital inputs and outputs . 59 Carry out material setup.................................... 13
Inputs......................................................... 59 Commissioning ................................................... 9
Outputs...................................................... 66 Select .................................................................. 9
Signification of the error messages........... 67 Sensor positioning device ................................. 15
Truth table ................................................. 63 Setting the actuator guiding direction ............... 11
Control loop settings......................................... 37 Setting the actuator path limits ......................... 11
Sensor positioning device ................................ 39 Settings centre position and gain for ................ 12
Setting the default values ................................. 27 Special functions............................................... 19
Special device settings ..................................... 68
Special functions .............................................. 56
System parameters .......................................... 27
Web width measurement.................................. 51
1 Internal connection
to terminal 8
2 IR pulse + 5 V/
Synchronisation for US sensor
X50 3 IR pulse GND
4 + 12 V Output + 12 V
5 GND
6 - 12 V Output – 12 V
7 Analog input 4
8 Internal connection
to terminal 1
9 IR pulse +5V/
Synchronisation for US sensor
X51 10 IR pulse GND
11 +12V Output ±12V
12 GND
13 -12V Output -12V
14 Analog input 6
B 4.2.4 Terminal strip X3; Position controller (SC) / servo-center component OMG 4 / Namur:
15 +5V / 1A
16 GND (+5V)
17 +12V Output ±12V
18 GND
19 -12V Output -12V
20 Analog input 7 Sensor 3
21 Analog input 1 EFE1 / OZ3
39 6 Winding 1B
X65 Shield Shield The shield is not
attached. The end of
the line must be
correctly stripped back
and insulated by using
sleeves against short
circuits caused by the
screen.
B 4.2.14 Terminal strips X17, X18, X19; Power supply (24V output for camera)
The controller is connected to the CAN bus via a 5-pin M12 micro
style connector.
4 3 3 4
5 5
1 2 2 1
Socket Plug
(female) (male)
ON Digital output 0 ON
ON Digital output 1 ON
ON Digital output 2 ON
ON Digital output 3 ON
Section C
Operation
C1 Controls
C2 Operation
C3 Error messages
C4 Maintenance
Section C
Operation
Table of contents
C2 Operation C2-1
C 2.1 General information C2-1
C 2.1.1 Graphics display C2-1
C 2.2 Changing the settings during operation C2-5
C 2.2.1 Operating functions C2-5
C 2.2.2 Scan start C2-6
C 2.2.3 Gain adjustment C2-7
C 2.2.4 Changing the settings C2-7
C 2.3 Sensor positioning device C2-8
C 2.3.1 Use of FVG functionality, general C2-8
C 2.3.2 Use of FVGPro 2MK functionality C2-8
C 2.3.3 Arrow key functions and the functions of the C2-8
digital inputs
C 2.4 Material set-up C2-10
C 2.4.1 Automatic material set-up C2-11
C 2.4.2 Manual material set-up C2-11
C 2.4.3 Special procedure if an analog reflecting sensor C2-12
is connected as Sensor 3
C 2.4.4 Manual material set-up for sensors C2-12
T 62 D 1 and TW 54 C5
C 2.4.4.1 Settings for the T 62 D 1 C2-13
C 2.4.4.2 Material set-up C2-14
C 2.5 Tear-off detection C2-15
C 2.6 Oscillation C2-16
C 2.7 Pre-positioning C2-17
C 2.8 Pre-positioning to machine centre C2-18
C 2.9 Unit remote control via CAN bus C2-19
C4 Maintenance C4-1
C 4.1 ekrPro Com60 controller C4-1
C 4.2 Sensors C4-1
C 4.3 Electric motor powered actuator C4-1
C 4.4 Hydraulically powered actuator C4-1
C 4.5 FVG-stepping motor C4-1
Keypad
The controller can be configured for operation using this keypad.
Key Function
Automatic guiding
Manual positioning
Key Function
Menu selection
Shortcut functions
Current position
1
in device menu
Assignment of allocated
function keys
61
12 3 45 6 789 0
The required dialog will be displayed and you can now use the
arrow keys to select the parameter that has to be modified.
The parameter values are entered directly in the editing box. This
can also be realised using the F-keys.
1. Open the required sub-menu and then press the ENTER key
to activate the editing box.
Control elements
Use the arrow keys to mark the required control if there are several
control elements displayed in the same dialog window.
For example:
sens.mode W XP
0 5.00
0 5.00
0 5.00
0 5.00
Option lists
An entry from a default list can be selected from an option list. This
is realised by pressing the ENTER button to open the selected
option list.
Example:
EMS 17 EMS 10
EMS 16
EMS 17
The “▼“ or “▲“ symbols displayed on the right of the option list
indicate that there are more entries in list than are displayed on the
screen.
Checkbox
Example:
X = Option active
active X
= Option inactive
Read-only Checkbox
Example:
= actuated
= not actuated
Editing box
The arrow keys can also be used to enter a value in the editing box
in addition to using the F-keys.
C 1.2.3 Buttons
Button control elements are present in certain dialog windows
=
ekrPro Com60 web guide controller EDV-No.: MD.191.00.05/1.6.x Chapter: C1
with analog sensors Date: 23.11.2007 Page: 6/6
Operation C2
C 2 Operation
C 2.1 General information
C 2.1.1 Graphics display
The various operating statuses are displayed by the graphics
display.
Use the vertical arrow keys to change between the different
displays in normal control mode.
The number of displays varies between one and four, depending
on whether a sensor adjustment unit and/or sensor 3 is
interconnected or not.
Information for the assigned operating mode is shown in the
separate displays and their significances are explained in the
following.
Switching between
operating displays
Switching between
operating displays
Actuator is blocked
Switching between
operating displays
Display of pre-positioning
Display when using internal sensor positioning device (normally FVG 1MK)
Switching between
operating displays
Switching between
operating displays
Automatic mode
Manual positioning
1)
Press the “MAN“ key.
Centre positioning
Press the SET-UP button and the parameters displayed in the line
at the bottom of the screen will change from the displayed setpoint
(W) to the gain setting (XP).
The controller gain can now be modified using the horizontal arrow
keys. The new setting will have an immediate effect on the
controller.
The setting can now be modified using the horizontal arrow keys.
The new setting will have an immediate effect on the controller.
The function of the arrow keys are generally changed using the
SETUP button.
The arrow keys act upon the web position or the controller gain in
the AUTO mode of operation. The type of web adjustment
depends on the set FVG mode.
The buttons act upon the actuator in the MAN mode of operation.
They act upon the FVG after pressing the button SETUP, in the
settings Man.Sensor Positioning.
FVG mode available options for the available options for the digital inputs
keyboard arrow keys
terminal 80 = Low terminal 80 = High
w w w
not
connected switch over via SETUP button
xp
FVG eco w w FVG
switch over via SETUP button
xp
switch over via SETUP button
FVG
FVG 1MK with centreline guiding
w
switch over via SETUP button w (with centreline guiding) w (with centreline guiding)
xp
with edge guiding
xp
switch over via SETUP button FVG (with edge guiding) FVG (with edge guiding)
FVG
FVG 2MK xp FVG FVG
switch over via SETUP button
FVG
FVG
FVG 1MK
mot (actuator) actuator actuator
FVG 2MK mot (actuator) actuator actuator
switch over via SETUP button
FVG1
switch over via SETUP button
FVG2
Requirement:
The user level “Mainten” must be active.
<<<
7%
dark bright Material set-up can now be carried out either automatically or
-2048 abs. 1775 2047
auto dark bri.
manually.
The manual procedure should always be used if the contrast that
has to be scanned is critical.
This completes the material set-up for this sensor. Material set-up
has been completed when the same procedure has been carried
out for any other sensors connected to the controller.
Line
Light spot
b) Contrast scanning
The switch on the casing to be switched to “Kante” (edge) mode.
Set the sensor in a manner for ensuring that the contrast to be
scanned is in the centre of the light spot. Then extinguish both
luminous diodes by employing the “Nullpunktabgleich” (zero
alignment) potentiometer on the sensor. We recommend that the
zero point compensation is carried out with inclined sensor (the tilt
position must be determined empirically) when both LED´s
illuminate as a result of intensive surface reflections (e.g. metal
foils).
Contrast
Light spot
LEDs
Changeover switch
contrast/line
Zero alignment
60
ekrPro Com web guide controller EDV-No.: MD.191.01.05/1.6.x Chapter: C2
with analog sensors Date: 23.11.2007 Page: 13/19
Operation C2
C 2.4.4.2 Material set-up
For critical contrast transitions, this function enables
optimum adjustment of the reflection sensor TW 54 C5 or
the line sensor T 62 D 1 to the properties of the material to
be scanned.
In addition to the normal material setup, the offset value and
gain for sensor 3 can also be set here.
Offset 3 Gain
0 1.00
6. Position the sensor’s light spot
Of.- Of.+ Ga.- Ga.+
on the dark contrast area.
Interrupted printed
or contrast edge
Tear-off
inwards
Tear-off
outwards
C 2.6 Oscillation
The function ”oscillation“ enables a position displacement of the
material web within the sensor scanning area with adjustable
amplitude (size of the transverse displacement) and frequency
(speed of the displacement).
The amplitude of the oscillation can be set separately for the
operating modes "automatic" and "SC".
Activate oscillation
Deactivate oscillation
C 2.7 Pre-positioning
You can use this function to carry out material web pre-positioning
to a position determined by a user.
Both the guiding mode on which the pre-positioning is to be used
and the target web position itself can be set.
Example:
Both sensors start from the home position. Measure the distance
between the centre of the sensor measurement band of each FVG.
As an example, this distance is 1070 mm.
Halve the distance!
Machine centre
1070
C 3 Error reports
1. To acknowledge an error
The error report must be acknowledged by pressing the
‘ENTER‘ button and then the display and the error-LED will be
extinguished.
The error report will be displayed immediately after being
acknowledged if the error has not been eliminated.
2. Self-deleting errors
The error message is deleted automatically as soon as the error
is eliminated. The error LED will be extinguished.
- Insufficient contrast has been - Clean the sensor and repeat the
CONTRAST DIRT determined after a material material set-up.
set-up using the analog
sensors.
The setting will be imported,
but correct controlling cannot
be guaranteed.
The controller does not respond - A remote controller has been - Check terminal 85. Remove the
to any operation. connected to the control “1“ signal (24V DC) if present.
system.
It has blocked the controller
buttons.
Undefined unit response. - A program change has - Carry out a basic unit
occurred without a restart. initialisation.
A connected sensor is not - An incorrect type was - Set the correct sensor type
working entered in the set up menu (Menu General Setup >
for the corresponding sensor. Sensors/EFE).
The actuator moves to an end - The actuator direction is - Reverse the actuator direction
position and remains there in the incorrectly set. (Menu General Setup >
operating modes "manual Actuator > Direction,
operation" or "SC". Checkbox "Mot Dir. Inverted“).
Both software end switches of - The direction of the position - Reverse the position feedback
the actuator are active return for the central position direction
simultaneously. encoder is incorrectly set. (Menu General Setup >
Actuator > SC-Transducer >
Type & Dir., Checkbox "Inv“).
All the menu settings for - The gain (XP) was - Adjust the controller gain.
actuators, sensors, central inadvertently reduced to “0”.
position encoders, etc. are No guiding takes place in
correct, but the unit does not "automatic" operating mode.
control
The control unit cannot or can - Changes to the settings of the - Check the configuration of all
only be partially controlled after digital inputs have been digital inputs and if necessary
switching on. carried out (e.g. an input for adjust a possibly present
an operating mode has been external protective circuit
configured as Low-active, so (Menu General Setup >
that the operating mode can Dig. > Inputs).
no longer be changed over
the keyboard).
C 4 Maintenance
Beware!
The controller has to be switched off!
C 4.2 Sensors
The sensor lenses have to be kept clean to ensure optimum
guiding results.
C 4.4 Hydraulically
powered actuator
The hydraulically powered actuator is maintenance-free.
Section D
Appendix
D1 To open the set-up menu
D2 Default settings
D3 Commissioning example
D4 Connection diagram / Plug assignments
D5 System overview
D6 Flange board connection
3. Go to General Setup > Actuator > SC-Transducer > Type & Dir.
and select and enter the servo-center component.
3. Go to General Setup > Actuator > SC-Transducer > Type & Dir.
and deactivate the servo-center component, i.e. select and enter
“not connected“ in the options list.
After this, the Master setup for this sensor has to be carried out.
Press the F1 („auto“) button. Then cover up the sensor measuring
window completely and then hold it free. Press key F2 ("auto OK“)
to confirm.
9. Now, the FVGPro 2/MK has been made completely ready for
operation.
Once the basic settings have been made for the FVGPro 2/MK, you
can now carry out additional functionalities such as material width
measurement, pre-positioning etc.
EFE1
Analog sensors
230 V
FVGPro module
Line sensor/
Reflection sensor
Appendix D 5: System overview
EDV no.: MD.191.01.05/1.6.x Issued: 23.11.2007 Hydraulic system
Flange connection plate D6
X50 X51
X60 X100
External 24 VDC
X65
X101
X70 X71